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WO1996020370A1 - Dispositif optique comportant une pluralite d'unites dotees d'au moins deux guides d'ondes optiques effiles se distinguant par leur geometrie - Google Patents

Dispositif optique comportant une pluralite d'unites dotees d'au moins deux guides d'ondes optiques effiles se distinguant par leur geometrie Download PDF

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Publication number
WO1996020370A1
WO1996020370A1 PCT/US1995/015976 US9515976W WO9620370A1 WO 1996020370 A1 WO1996020370 A1 WO 1996020370A1 US 9515976 W US9515976 W US 9515976W WO 9620370 A1 WO9620370 A1 WO 9620370A1
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WO
WIPO (PCT)
Prior art keywords
waveguides
waveguide
light
surface area
tapered
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US1995/015976
Other languages
English (en)
Inventor
Paul Ferm
Scott Zimmerman
Karl Beeson
John Schweyen
Okan Tezucar
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Honeywell International Inc
Original Assignee
AlliedSignal Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by AlliedSignal Inc filed Critical AlliedSignal Inc
Priority to AU45121/96A priority Critical patent/AU4512196A/en
Priority to JP52046796A priority patent/JP3749542B2/ja
Priority to DE69511113T priority patent/DE69511113T2/de
Priority to EP95943716A priority patent/EP0799398B1/fr
Publication of WO1996020370A1 publication Critical patent/WO1996020370A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • G—PHYSICS
    • G09—EDUCATION; CRYPTOGRAPHY; DISPLAY; ADVERTISING; SEALS
    • G09F—DISPLAYING; ADVERTISING; SIGNS; LABELS OR NAME-PLATES; SEALS
    • G09F13/00—Illuminated signs; Luminous advertising
    • G09F13/04—Signs, boards or panels, illuminated from behind the insignia
    • G09F13/0409—Arrangements for homogeneous illumination of the display surface, e.g. using a layer having a non-uniform transparency
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V5/00—Refractors for light sources
    • F21V5/02—Refractors for light sources of prismatic shape
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/04—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings formed by bundles of fibres
    • G02B6/06—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings formed by bundles of fibres the relative position of the fibres being the same at both ends, e.g. for transporting images
    • G02B6/08—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings formed by bundles of fibres the relative position of the fibres being the same at both ends, e.g. for transporting images with fibre bundle in form of plate
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/10—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings of the optical waveguide type
    • G02B6/12—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings of the optical waveguide type of the integrated circuit kind
    • G02B6/122—Basic optical elements, e.g. light-guiding paths
    • G02B6/1221—Basic optical elements, e.g. light-guiding paths made from organic materials
    • G—PHYSICS
    • G02—OPTICS
    • G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B6/00—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings
    • G02B6/10—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings of the optical waveguide type
    • G02B6/12—Light guides; Structural details of arrangements comprising light guides and other optical elements, e.g. couplings of the optical waveguide type of the integrated circuit kind
    • G02B6/122—Basic optical elements, e.g. light-guiding paths
    • G02B6/1228—Tapered waveguides, e.g. integrated spot-size transformers
    • G—PHYSICS
    • G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
    • G03B—APPARATUS OR ARRANGEMENTS FOR TAKING PHOTOGRAPHS OR FOR PROJECTING OR VIEWING THEM; APPARATUS OR ARRANGEMENTS EMPLOYING ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ACCESSORIES THEREFOR
    • G03B21/00—Projectors or projection-type viewers; Accessories therefor
    • G03B21/54—Accessories
    • G03B21/56—Projection screens
    • G03B21/60—Projection screens characterised by the nature of the surface
    • G03B21/62—Translucent screens
    • G03B21/625—Lenticular translucent screens
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S385/00—Optical waveguides
    • Y10S385/901—Illuminating or display apparatus

Definitions

  • the present invention relates to an optical device comprising a plurality of units having at least two geometrically-differentiated tapered optical waveguides therein.
  • Optical waveguides also known in the art as light transmissive devices or lightguides, find application in display devices, such as for example projection display devices, off screen display devices, and direct view displays.
  • display devices such as for example projection display devices, off screen display devices, and direct view displays.
  • an optical element having a plurality of optical waveguides is used. See for example U.S. Patents 3,218,924 and 3,279,314 to Miller and U.S. Patent 4,767,186 to Bradley, Jr. et al.
  • Such displays are used in a wide range of applications including computer terminals, airplane cockpit displays, automotive instrument panels, televisions, and other devices that provide text, graphics, or video information.
  • known displays may produce non-monotonically decreasing light output intensity as the viewing angle is changed from normal to the optical device to parallel to the optical device. See Figure 10 which shows the minima which occur in such a light distribution output pattern. A viewer will perceive the peaks between such lows in the light distribution output pattern as intensity hot spots, which will be clearly disadvantageous to the perception of a uniformly emissive optical device.
  • a typical liquid crystal display device has a first polarizer element, a first substrate with pixel electrodes on it and a matrix circuit section to apply voltage to these pixel electrodes, a liquid crystal layer, a second substrate having a black matrix layer with openings, and a second polarizer element.
  • a pixel is formed by the openings on the second substrate and the pixel electrodes on the first substrate.
  • the optical device comprises: (a) a substrate; and (b) a plurality of units on the substrate.
  • Each of the units comprises a plurality of tapered waveguides wherein: (i) each of the waveguides has a light input surface adjacent the substrate (a) and a light output surface distal from the light input surface and the light input surface area is greater than the light output surface area; (ii) each of the waveguides tapers from its light input surface to its light output surface; and (iii) at least one of the light input surface area or the light output surface area of at least one of the tapered waveguides is different than the corresponding surface area of the remaining tapered waveguides in the unit.
  • the present optical device When used as a viewing film, the present optical device is particularly advantageous. Because at least one of the light input and output surface areas of at least one of the tapered waveguides is different than the corresponding surface area of the remaining tapered waveguides in the unit, the occurrence of intensity hot spots and Moire and interference patterns is reduced or substantially eliminated. As a result, the viewing film provides a more uniformly emissive display.
  • Figure 1 illustrates a tapered optical waveguide element with a rectangular or square base useful in the present invention.
  • Figure 2 illustrates a tapered optical waveguide element with a circular base useful in the present invention.
  • Figure 3 illustrates the taper angle, light input surface dimension, and light output surface dimension of the tapered optical waveguide element.
  • Figure 4 illustrates the side view of a unit of two tapered optical waveguide elements which have different light output surface areas and identical light input surface areas.
  • Figure 5 illustrates a perspective view of the unit of the two different tapered optical waveguide elements of Figure 4.
  • Figure 6 illustrates the side view of a unit of two tapered optical waveguide elements which have different light input and output surface areas.
  • Figure 7 illustates the design of a lithographic phototool which was used to photolithographically define 16 different optical waveguides as the repeat unit of a viewing film.
  • Figure 8 illustrates one possible arrangement of tapered optical waveguide elements within a unit 26 which contains different light input surface areas 14a and 14b and different light output areas 16a-16d.
  • Figure 9 illustrates the resulting light distribution of the tapered optical waveguide element having a square output surface area which is 25 microns on a side used in Example 1.
  • Figure 10 illustrates the resulting light distribution of the tapered optical waveguide element having a square output surface area which is 10 microns on a side used in Example 1.
  • Figure 1 1 illustrates a top view of a unit 26 of four different optical waveguide elements. In each case (a) - (e), the input surface areas 14 and the output surface areas 16 are noted. The successive figures show possible ways of creating units 26 in which combinations of two different output surface areas 16a and 16b are considered.
  • Figure 12 illustrates the resulting distribution from combining the tapered optical waveguide elements as depicted in Figure 11 (c).
  • Figure 13 illustrates the resulting distribution from combining the tapered optical waveguide elements as depicted in Figure 1 1 (d).
  • Figure 14 illustrates the resulting distribution from combining the tapered optical waveguide elements as depicted in Figure 1 1 (e).
  • Figure 15 illustrates the top view schematic representation of the resulting optical device described in Example 2.
  • each tapered waveguide 12 has a light input surface 14, light output surface 16, and sidewalls 18.
  • the area of light input surface 14 is greater than the area of light output surface 16 for each tapered waveguide 12.
  • the cross section of a tapered waveguide 12 in a plane parallel to the substrate surface may have any shape including a circle, square, hexagon, ellipse, and rectangle.
  • Figure 1 shows a tapered waveguide 12 with a rectangular cross section viewed in perspective.
  • Figure 2 shows a tapered waveguide 12 with a circular cross section viewed in perspective.
  • the shape of sidewalls 18 may be straight or curved.
  • each tapered waveguide 12 is preferably from about 1 to about 50 percent of the area of light input surface 14, more preferably from about 3 to about 25 percent of the area of light input surface 14, and most preferably from about 4 to about 12 percent of the area of light input surface 14.
  • the sum of the areas for all waveguide light input surfaces is preferably greater than about 40 percent of the total areas of the substrate of the viewing film, more preferably greater than about 60 percent of the total areas of the substrate of the viewing film, and most preferably greater than about 80 percent of the total areas of the substrate of the viewing film.
  • tapered waveguide 12 with light input surface 14, light output surface 16, and straight sidewalls 18 is shown in Figure 3. If tapered straight sidewalls 18 are extended until they intersect, they form taper angle 20.
  • the value of taper angle 20 ranges preferably from about 2 degrees to about 14 degrees, more preferably from about 4 degrees to about 12 degrees, and most preferably from about 6 degrees to about 10 degrees.
  • Tapered waveguide 12 has a height 22.
  • Dimension 24 is the minimum transverse distance across the waveguide light input surface 14. For example, if light input surface 14 has the shape of a square, dimension 24 is the length of one side of the square. As another example, if light input surface 14 has the shape of a rectangle, dimension 24 is the smaller of the two side dimensions of the rectangle.
  • the specific values for dimension 24 may vary widely depending on the center-to-center distance between adjacent pixels of a modulating means. In order that the resolution of the image formed by a modulating means not be degraded, dimension 24 should be equal to or less than the center-to-center distance between adjacent pixels of a modulating means.
  • dimension 24 is preferably in the range from about 5 microns to about 200 microns, more preferably in the range from about 15 microns to about 200 microns, and most preferably from about 25 microns to about 100 microns.
  • height 22 may be specified by the ratio of height 22 to dimension 24.
  • the ratio of height 22 to dimension 24 may vary widely depending on how much one wishes to increase the angular distribution of light emerging from the light output surface 16 compared to the angular distribution of light entering light input surface 14.
  • the ratio of height 22 to dimension 24 is preferably from about 0.25 to about 20, more preferably from about 1 to about 8, and most preferably from about 2 to about 6.
  • At least one of the light input surface area 14 or the light output surface area 16 of at least one of the tapered waveguides 12 is different than the corresponding light input surface area or light output surface area of the remaining tapered waveguides in the unit.
  • the term "different" as used herein means that at least one of the light input surface area or light output surface area of at least one of the tapered waveguides is different than the corresponding light input surface area or light output surface area of the remaining tapered waveguides in the unit by at least about 2 percent. For example, if the light input surface area of one of the tapered waveguides is x, each light input surface area of the remaining tapered waveguides in the unit is at least 1.02x or no more than 0.98x.
  • each light output surface area of the remaining tapered waveguides in the unit is at least 1.02y or no more than 0.98y. At least one of the light input surface area or light output surface area of at least one of the tapered waveguides is different than the corresponding light input surface area or light output surface area of the remaining tapered waveguides in the unit by preferably at least about 5 percent, more preferably at least about 10 percent, and most preferably at least about 20 percent.
  • the different surface areas include the following: (1) at least one light input surface area of at least one tapered waveguide is different than each light input surface area of the remaining tapered waveguides in the unit, (2) at least one light output surface area of at least one tapered waveguide is different than each light output surface area of the remaining tapered waveguides in the unit, and (3) both the light input and output surface areas of at least one tapered waveguide are different than both the light input and output surface areas of the remaining tapered waveguides in the unit.
  • Figure 4 illustrates the side view of a unit 26 of a plurality of two tapered waveguides 12 which have different light output surface areas 16, the same light input surface areas 14, and the same heights 22.
  • Figure 5 illustrates a perspective view of the unit 26 of Figure 4.
  • Figure 6 illustrates the side view of a unit 26 of a plurality of two tapered waveguides 12 which have different light input surface areas 14, different light output surface areas 16, and the same heights 22.
  • At least two of the tapered waveguides 12 in a unit have at least one of their light input surface areas 14 or their light output surfaces area 16 which are different than the corresponding light input surface areas or light output surface areas of the remaining tapered waveguides in the same unit and more preferably, they also have light input surface areas 14 or light output surface areas 16 which differ from each other.
  • each tapered waveguide 12 in a unit has at least one of its light input surface area 14 or its light output surface area 16 which is different than the corresponding light input surface area or light output surface area of every other tapered waveguide in the same unit.
  • the tapered waveguides 12 may have any shape including but not limited to rectangle, square, circle, ellipse, and hexagon. Within a unit 26, the tapered waveguides 12 may have the same shape or although not illustrated, the tapered waveguides 12 may have different shapes. For example, within a unit 26, one tapered waveguide 12 may have a rectangular cross section while a second tapered waveguide 12 may have a circular cross section. Most preferably, the shapes of the tapered waveguides 12 are selected so as to maximize the fill factor which is the sum of all the light input areas divided by the unit area.
  • the different shapes of the cross section of the tapered waveguides within a unit include the following: Rectangle Square Circle Ellipse Hexagon
  • At least one At least one waveguides waveguide waveguide
  • At least one At least one waveguides waveguide waveguide waveguide waveguide waveguide 73 Remaining At least one At least one waveguides waveguide waveguide waveguide waveguide waveguide
  • each tapered waveguide has a shape which is different than the shape of every other tapered waveguide in the same unit.
  • the tapered waveguides 12 are made of transparent solid polymer materials which have an index of refraction between about 1.45 and about 1.65 and include commercially available polymethylmethacrylate, poly(4-methylpentene), polycarbonate, polyester, polystyrene, and polymers formed by photopol ⁇ merization of acrylate or methacrylate monomers.
  • the tapered waveguides are made of a photopolymerizable material which comprises two essential ingredients.
  • the first essential ingredient is a photopolymerizable monomer, especially an ethylenically unsaturated monomer which will provide a transparent solid polymer material.
  • More preferred materials have an index of refraction between about 1.50 and about 1.60 and include polymers formed by photopolymerization of acrylate or methacrylate monomer mixtures composed of urethane acr ⁇ lates or urethane methacr ⁇ lates, ester acr ⁇ lates or ester methacrylates, epoxy acr ⁇ lates or epox ⁇ methacr ⁇ lates, pol ⁇ (eth ⁇ lene glycol) acrylates or pol ⁇ (eth ⁇ len ⁇ glycol) methacrylates or vin ⁇ l containing organic monomers.
  • Examples of useful more preferred monomers include methyl methacrylate; n-butyl acr ⁇ late (BA); 2-eth ⁇ lhex ⁇ l acrylate (EH A); isodecyl acr ⁇ late; 2-h ⁇ drox ⁇ eth ⁇ l acrylate; 2-h ⁇ drox ⁇ prop ⁇ l acr ⁇ late; c ⁇ clohex ⁇ l acr ⁇ late (CHA); 1 ,4-butanediol diacr ⁇ late; ethox ⁇ lated bisphenol A diacr ⁇ late; neopent ⁇ lgl ⁇ col diacr ⁇ late (NPGDA); dieth ⁇ lenegl ⁇ col diacr ⁇ late (DEGDA); dieth ⁇ lene gl ⁇ col dimethacr ⁇ late (PEGDMA); 1 ,6- hexanediol diacr ⁇ late (HDDA); trimeth ⁇ lol propane triacr ⁇ late (TMPTA); pentaer
  • the most preferred materials for use in the present invention are crosslinked pol ⁇ mers formed b ⁇ photopol ⁇ merizing mixtures of ethox ⁇ lated bisphenol A diacr ⁇ late and trimethylol propane triacr ⁇ late.
  • the index of refraction of the most preferred materials ranges from about 1.53 to about 1.56. It is not essential that the refractive index of the transparent solid material be homogeneous throughout the waveguide element. It ma ⁇ be advantageous to cause to be present, inhomogeneities in refractive index, such as striations or scattering particles or domains, as these inhomogeneities ma ⁇ further increase the divergence of light from the output of the waveguides.
  • the amount of monomer in the photopolymerizable material may var ⁇ widel ⁇ .
  • the amount of monomer or the total amount of a mixture of monomers is usuall ⁇ from about 60 to about 99.8 percent b ⁇ weight of the photopol ⁇ merizable material, preferabl ⁇ from about 80 to about 99 percent b ⁇ weight of the photopolymerizable material, and more preferably from about 85 to about 99 percent by weight of the photopolymerizable material.
  • the pol ⁇ merizable material includes a photoinitiator which is activated b ⁇ actinic radiation to produce activated species which lead to photopol ⁇ merization of the monomer.
  • the photoinitiator s ⁇ stem will contain a photoinitiator and preferabl ⁇ a conventional sensitizer which extends the spectral response into regions having spectral utilit ⁇ , e.g. the near ultraviolet region and the visible spectral regions where lasers excite and where man ⁇ common optical materials are transmissive.
  • the photoinitiator is a free radical-generating addition pol ⁇ merization initiator activated b ⁇ actinic light and is preferabl ⁇ thermall ⁇ inactive at and below room temperature (e.g. about 20°C to about 25°C.)
  • Preferred free radical initiators are 1 -h ⁇ drox ⁇ -c ⁇ clohex ⁇ l-phen ⁇ l ketone (Irgacure 184); benzoin; benzoin eth ⁇ l ether; benzoin isoprop ⁇ l ether; benzophenone; benzidimeth ⁇ l ketal (Irgacure 651 ); ⁇ , ⁇ -dieth ⁇ lox ⁇ acetophenone, ⁇ , ⁇ -dimeth ⁇ lox ⁇ - ⁇ -h ⁇ drox ⁇ acetophenone (Darocur 1 173); 1-[4-(2-h ⁇ drox ⁇ ethox ⁇ )phen ⁇ l]-2-h ⁇ drox ⁇ - 2-meth ⁇ l-propan-1-one (Darocur 2959); 2-meth ⁇ l-1-[4-meth ⁇ lthio)phen ⁇ l]- 2-morpholino-propan-1-one (Irgacure 184); benzoin; benzoin eth ⁇ l ether; benzoin isoprop ⁇
  • the more preferred photoinitiators includes benzidimeth ⁇ l ketal (Irgacure 651); ⁇ , ⁇ -dieth ⁇ lox ⁇ acetophenone; ⁇ , ⁇ -dimeth ⁇ lox ⁇ - ⁇ -h ⁇ drox ⁇ acetophenone (Darocur 1 173); 1 -hydrox ⁇ -c ⁇ cloh ⁇ x ⁇ l-phe ⁇ l ketone (Irgacure 184); 1 -[4- ⁇ 2-h ⁇ drox ⁇ ethox ⁇ )phen ⁇ l]-2-h ⁇ drox ⁇ -2-meth ⁇ l- propan-1 -one (Darocur 2959); 2-meth ⁇ l-1-4-(meth ⁇ lthio)ph ⁇ n ⁇ l]-2- morpholino-propan-1-one (Irgacure 907); 2-b ⁇ nz ⁇ l-2-dimeth ⁇ lamino-1-(4- morpholinophen ⁇ l)butan-1-one (Irgacure 369); and
  • the most preferred photoinitiators are those which tend not to yellow upon irradiation and, thus, do not increase the coloration of the composition on the Gardner scale to a value of greater than 8 points on exposure to a temperature of 190°C for 24 hours as determined by ASTM D 1544-80.
  • Such photoinitiators include benzidimeth ⁇ l ketal (Irgacure 651); ⁇ . ⁇ -dimeth ⁇ lox ⁇ -a-h ⁇ drox ⁇ acetophenone (Darocur 1 173); 1 -h ⁇ drox ⁇ -c ⁇ clohex ⁇ l-phen ⁇ l ketone (Irgacure- 184); 1 -[4-(2- hydrox ⁇ ethox ⁇ )phen ⁇ l]-2-h ⁇ drox ⁇ -2-meth ⁇ l-propan-1 -one (Darocur 2959); and 50% 1 -h ⁇ drox ⁇ c ⁇ clohex ⁇ l phen ⁇ l ketone and 50% benzophenone (Irgacure 500).
  • benzidimeth ⁇ l ketal Irgacure 651
  • ⁇ . ⁇ -dimeth ⁇ lox ⁇ -a-h ⁇ drox ⁇ acetophenone Darocur 1 173
  • the amount of photoinitiator which must be present to form a gradient of substantiall ⁇ collimated ultraviolet light across the thickness of the photopolymerizable mixture is from about 0.1 to about 12 percent by weight based on the total weight of the photopol ⁇ merizable material.
  • the amount of photoinitiator is preferabl ⁇ from about 0.5 to about 12 percent b ⁇ weight, and more preferabl ⁇ from about 0.5 to about 8 percent b ⁇ weight based on the total weight of the photopol ⁇ merizable material. It is realized that the desired gradient will be influenced not onl ⁇ b ⁇ the concentration of the initiator but b ⁇ the choice of irradiating wavelengths present in the exposure source, which ma ⁇ be controlled b ⁇ those skilled in the art.
  • the photopolymerizable material ma ⁇ include various optional ingredients such as stabilizers, inhibitors, plasticizers, optical brighteners, release agents, chain transfer agents, other photopol ⁇ merizable monomers, and the like.
  • the photopol ⁇ merizable material preferabl ⁇ includes a stabilizer to prevent or reduce degradation which leads to propert ⁇ deterioration such as cracking and deiamination after heat aging at 190°C in air for 24 hrs. as defined b ⁇ ASTM D 4538-90A and ⁇ ellowing (coloration of greater than 8 on the Gardner Color Scale as determined b ⁇ ASTM D 1544-80) after such heat aging.
  • stabilizers include UV absorbers, light stabilizers, and antioxidants.
  • UV absorbers include h ⁇ drox ⁇ phen ⁇ l benzotriazoles, such as 2-[2- h ⁇ drox ⁇ -3,5-di(1 ,1-dimeth ⁇ lbenz ⁇ l)phen ⁇ l]-2-H-benzotriazole (Tinuvin 900); Pol ⁇ (ox ⁇ -1 ,2-ethanedi ⁇ l), ⁇ -(3-(3-(2H-benz ⁇ otriazol-2- ⁇ l)-5-(1 , 1- dimeth ⁇ leth ⁇ l)-4-h ⁇ drox ⁇ phen ⁇ l)-1-oxoprop ⁇ l)- ⁇ -h ⁇ drox ⁇ (Tinuvin 1 130); and 2-[2-h ⁇ drox ⁇ -3,5-di(1 ,1-dimeth ⁇ lprop ⁇ l)phen ⁇ l]-2-H-benzotriazole (Tinuvin 238) and h ⁇ drox ⁇ benzophenones such as 4-methox ⁇ -2- h ⁇ drox ⁇ benzophenone and 4-n-o
  • Light stabilizers include hindered amines such as 4-h ⁇ drox ⁇ -2, 2,6,6- tetrameth ⁇ lpiperidine, 4-h ⁇ drox ⁇ -1 ,2,2,6,6-pentameth ⁇ ipiperidine, 4- benzo ⁇ lox ⁇ -2,2,6,6-tetrameth ⁇ lpiperidine, bis(2,2,6,6-tetrameth ⁇ l-4- piperidin ⁇ Dsebacate (Tinuvin 770); bis(1 , 2,2,6, 6-pentameth ⁇ l-4- piperidin ⁇ Dsebacate (Tinuvin 292); bis(1 ,2,2,6,6-pentameth ⁇ l-4- piperidin ⁇ l)-2-n-but ⁇ l-2-(3,5-di -tert-but ⁇ l-4-h ⁇ drox ⁇ benz ⁇ l)malonate (Tinuvin 144); and pol ⁇ ester of succinic acid with N- ⁇ -h ⁇ drox ⁇ -eth ⁇ l- 2,2,6,6
  • Antioxidants include substituted phenols such as 1 ,3,5-trimeth ⁇ l-2,4,6-tris(3,5-di-tert- but ⁇ l)-4-h ⁇ drox ⁇ benz ⁇ l)benzene, 1 , 1 ,3-tris-(2-meth ⁇ l-4-h ⁇ drox ⁇ -5-tert- but ⁇ l)phen ⁇ l)butane, 4,4'-but ⁇ lidene-bis-(6-tert-but ⁇ l-3-meth ⁇ l)phenol, 4,4 * -thiobis-(6-tert-butyl-3-meth ⁇ l)phenol, tris-(3,5-di-tert-but ⁇ l-4- h ⁇ drox ⁇ benz ⁇ Disoc ⁇ anurate, cetyl-3,5-di-tert-but ⁇ l-4-h ⁇ drox ⁇ benzene (C ⁇ asorb UV2908); 3,5-di-tert-but ⁇ l-4-h ⁇ drox ⁇ benzoic acid, 1 ,3,5
  • the preferred stabilizers used in this invention are antioxidants.
  • Preferred antioxidants are selected from substituted phenols such as 1 ,3,5-trimeth ⁇ l-2,4,6-tris(3,5-di-tert-but ⁇ l)-4-h ⁇ drox ⁇ benz ⁇ l)benzene, 1 ,1 ,3-tris-(2-meth ⁇ l-4-h ⁇ drox ⁇ -5-tert-but ⁇ lph ⁇ n ⁇ l)butane, 4,4'-but ⁇ lidene- bis-(6-tert-but ⁇ l-3-meth ⁇ lphenol, 4,4'-thiobis-(6-tert-but ⁇ l-3-meth ⁇ lphenol, tris-(3,5-di-tert-but ⁇ l-4-h ⁇ drox ⁇ benz ⁇ l)isoc ⁇ anurate, cet ⁇ l-3,5-di-tert- but ⁇ l-4-h ⁇ drox ⁇ benzene (C ⁇ asorb UV 2908); 3,5-di-tert-but ⁇ l
  • the most preferred stabilizers include pentaer ⁇ thritol tetrabis(3,5-di-tert-but ⁇ l-4-h ⁇ drox ⁇ phen ⁇ l) (Irganox 1010); thiodieth ⁇ lene-bis-(3,5-di-tert-but ⁇ l-4-h ⁇ drox ⁇ )h ⁇ drocinnamate (Irganox 1035); and stear ⁇ l-3-(3,5-di-tert-but ⁇ l-4- h ⁇ drox ⁇ phen ⁇ Dproprionate (Irganox 1076).
  • the amount of stabilizers in the composition ma ⁇ var ⁇ widel ⁇ and is usually from about 0.1 to about 10 percent b ⁇ weight of the photopolymerizable material.
  • the amount of stabilizer is preferabl ⁇ from about 0.1 to about 5 percent b ⁇ weight of the photopol ⁇ merizable material and more preferabl ⁇ from about 0.2 to about 3 percent b ⁇ weight of the photopol ⁇ merizable material.
  • the tapered waveguides 12 ma ⁇ be manufactured on a substrate.
  • the tapered waveguides 12 ma ⁇ be manufactured b ⁇ a variet ⁇ of techniques including injection molding, compression molding, hot roller pressing casting, and photopol ⁇ merization processes.
  • a preferred technique is a photopol ⁇ merization process wherein the tapered waveguides 12 are formed b ⁇ ultraviolet light irradiation of a la ⁇ er of the photopol ⁇ merizable material through a patterned mask as described in co-pending Serial No. 08/148,794 filed November 8, 1993 which is incorporated herein b ⁇ reference.
  • a substrate is placed on top of a la ⁇ er of photopol ⁇ merizable material which, in turn, is placed over a bottom support plate having a release la ⁇ er.
  • the mask bears a pattern of opaque areas which allow ultraviolet light to pass through onl ⁇ in the areas which comprise the desired pattern of the tapered waveguides.
  • Ultraviolet light as from a mercur ⁇ or xenon lamp, is directed to fall on the surface of the mask.
  • Ultraviolet light which passes through the clear areas of the mask causes a photopol ⁇ merization reaction in the exposed regions of the photopolymerizable layer which are directl ⁇ under the clear image areas of the mask. No photoreaction occurs in those areas of photopol ⁇ merizable layer which are shielded from the ultraviolet light by the opaque areas of mask.
  • irradiation b ⁇ ultraviolet light both mask and bottom support plate with release la ⁇ er are removed.
  • the unreacted monomers are washed awa ⁇ with a suitable solvent such as acetone, methanol, or isopropanol leaving a pattern of photopol ⁇ merized regions on the substrate.
  • Photopol ⁇ merized regions correspond to the arra ⁇ of tapered waveguides of the present invention.
  • the optical absorption of the unreacted photopol ⁇ merizable la ⁇ er at the wavelengths of the ultraviolet light must be high enough such that a gradient of ultraviolet light intensit ⁇ is established through the film during ultraviolet light exposure. That is, the amount of ultraviolet light available in the monomer la ⁇ er to cause the initiation of the photoreaction will decrease from the top, or the image mask side, towards the bottom, or the bottom support plate side, due to the finite absorption of the monomer la ⁇ er.
  • This gradient of ultraviolet light causes a gradient in the amount of photopol ⁇ merization reaction that occurs from top to bottom, and this results in the unique tapered geometry of the developed waveguide structures, a geometr ⁇ which is easil ⁇ accessible with the method of the present invention.
  • the gradient in the amount of photopol ⁇ merizatiori which occurs from the top to the bottom of the film may be further influenced by the presence of dissolved oxygen gas in the photopol ⁇ merizable la ⁇ er, such ox ⁇ gen acting to curtail or quench the photopol ⁇ merization reaction except in those areas where all ox ⁇ gen has been consumed b ⁇ the free radicals produced in the photopol ⁇ merization process.
  • dissolved oxygen gas in the photopol ⁇ merizable la ⁇ er
  • Such action of dissolved ox ⁇ gen gas on the progress of photopol ⁇ merization reactions is well known to those skilled in the art.
  • the requisite geometry of the photopolymer structures ma ⁇ be further influenced b ⁇ the process of self -focussing.
  • the light falling on the surface of the monomer la ⁇ er initiates photopol ⁇ merization at that surface, and since the refractive index of the solidified pol ⁇ mer material is higher than that of the liquid monomer, it acts to refract the light passing through it.
  • the aerial image of light falling on the monomer nearer to the bottom of the monomer la ⁇ er is altered through refraction caused b ⁇ the already-polymerized material which lies above it. This effect may cause a narrowing of the resultant pol ⁇ merized structure from the top surface, upon which the imaging light was directed, towards the bottom, or support plate side of the layer.
  • the index of refraction of interstitial regions between the tapered waveguides must be less than the index of refraction of the tapered waveguides.
  • Preferred materials for interstitial regions include air, with an index of refraction of 1.00, fluoropolymer materials with an index of refraction ranging from about 1.30 to about 1.40, and silicone materials with an index of refraction ranging from about 1.40 to about 1.44.
  • the most preferred materials are air and fluorinated pol ⁇ urethane.
  • the interstitial regions between the tapered waveguides also comprise a light absorptive material, as for example light absorptive black paniculate material.
  • a light absorptive material as for example light absorptive black paniculate material.
  • the present viewing film provides higher contrast and less ambient light is reflected back to the observer. It is preferred that light absorptive particles be used for the interstitial regions rather than a continuous black material in order to minimize the area of black material in contact with side surfaces of the tapered waveguides. A continuous black material in interstitial regions would result in excess absorption loss to light transmitted through waveguides via the mechanism of frustrated internal reflection.
  • the light absorbing component is preferabl ⁇ maintained at least about 1 micron, and preferabl ⁇ greater than about 3 microns from the side surface of the waveguide.
  • An ⁇ light absorptive material ma ⁇ be used to form the particles.
  • useful light absorptive black paniculate material include carbon lampblack powder, mixtures of carbon black and toner, and mixtures of carbon black and fluoropol ⁇ mer.
  • the light absorptive black paniculate material causes the array to appear a dark matte black and provides good light transmission and little surface reflection (either specular or diffused) when observed from the viewer's side of the display device.
  • the total number of tapered waveguides 12 in each unit 26 is most preferabl ⁇ at least 2 or more.
  • a viewing film has a plurality of units 26 on a substrate and the total number of units 26 depends upon the desired final size of the viewing film. In the limiting case, each unit has an area equal to the entire displa ⁇ area and each waveguide is statistically different.
  • Figure 7 illustrates the top view of a lithographic phototool which was used to photolithographicall ⁇ define sixteen different tapered optical waveguides as the repeat unit 26 of an optical element.
  • the heavy dark lines indicate the dark areas of the photomask which in the lithography process define the input light surface area 14.
  • Example 2 will describe the result of having used this phototool.
  • the tapered waveguides 12 ma ⁇ be made on an ⁇ substrate.
  • the substrate is transparent to light within the wavelength range from about 400 to about 700 nm, as this visible wavelength region is the most desirable region in which the optical waveguides to be formed will operate. It is more preferred that the substrate also transmits ultraviolet light in the region from about 250 to about 400 nm as this is the region in which man ⁇ useful photoinitiators absorb light. Additionall ⁇ , if it is desired to utilize the present viewing film in the near infrared region, from about 700 nm to about 2000 nm, then it would be preferred to use a substrate which is transparent in that region as well.
  • the index of refraction of substrate ma ⁇ range from about 1.45 to about 1.65.
  • the most preferred index of refraction is from about 1.50 to about 1.60.
  • Preferred substrate materials are commercially available and include transparent polymers, glass, and fused silica.
  • Useful transparent polymers include polyesters such as polyethylene terephthalate) and poly (ethylene terephthalate glycol), polyacrylates and methacr ⁇ lates, pol ⁇ st ⁇ rene, and pol ⁇ carbonates. Desired characteristics of these materials include mechanical and optical stability at typical operating temperatures of the displa ⁇ device. Compared with glass, transparent pol ⁇ mers have the added advantage of structural flexibility which allows products to be formed in large sheets and then cut and laminated as necessary.
  • the preferred materials for substrate are glass and pol ⁇ ester such as polyethylene terephthalate.
  • the thickness of substrate ma ⁇ var ⁇ widel ⁇ . Preferabl ⁇ , the thickness of substrate is about 0.5 mil (.0005 inch or 12 microns) to about 10 mil (0.01 inch or 250 microns).
  • the tapered waveguides 12 ma ⁇ also be manufactured directl ⁇ on a polarizer element.
  • Figure 8 illustrates one possible arrangement of tapered optical waveguide elements within a unit 26 which contains different light input surface areas 14a and 14b and different light output areas 16a-16d.
  • the unit contains twelve tapered optical waveguide elements. Eight of those elements contain identical rectangular light input surface areas 14b. Of those eight elements, four contain narrow rectangular output light surface areas 16a and four others contain wide rectangular output light surface areas 16b. The remaining four elements contain identical square light input surface areas 14a. Of these four elements, two contain narrow square output light surface areas 16c and two others contain wide square output light surface areas 16d. Due to the mixture of rectangular elements and square elements, the resulting unit will have an output light distribution with a preponderance of light distributed into a direction perpendicular to the long axis of the rectangles. Figure 8 is meant to illustrate that an ⁇ combination of elements ma ⁇ be combined within a unit. The choice of units is made to tailor the distribution of light to meet the needs of the user.
  • Examples of useful adhesives for adhesive la ⁇ er include pressure sensitive adhesives, such as eth ⁇ lenic adhesives and vin ⁇ l acetate adhesives; thermosetting adhesives such as epoxies, urethanes, and silicones; and photopol ⁇ merizable adhesives, such as acr ⁇ lates, methacrylates, and urethanes and mixtures thereof.
  • pressure sensitive adhesives such as eth ⁇ lenic adhesives and vin ⁇ l acetate adhesives
  • thermosetting adhesives such as epoxies, urethanes, and silicones
  • photopol ⁇ merizable adhesives such as acr ⁇ lates, methacrylates, and urethanes and mixtures thereof.
  • adhesion promotion ma ⁇ be provided b ⁇ using an adhesion treated PET film such as Hostaphan 4500 (Hoechst-Celanese). If the substrate is emulsion coated, adhesion promotion ma ⁇ be provided b ⁇ 3-acr ⁇ lox ⁇ prop ⁇ itrichlorosilane (H ⁇ ls America A0396).
  • a protective la ⁇ er ma ⁇ be used over the output ends of the tapered waveguides 12 to prevent mechanical damage to the output surfaces of the tapered waveguides and also serve to confine light absorptive paniculate material to interstitial regions between tapered waveguides.
  • the protective la ⁇ er ma ⁇ be an extruded or laminated overcoat.
  • a protective la ⁇ er ma ⁇ also be applied to the output surfaces of the tapered waveguides 12 before filling the interstitial regions with a light absorptive black paniculate material.
  • Protective layer is composed of a transparent backing material as for example the material used to form support layer and optionally and preferabl ⁇ anti-reflective film formed from a material such as magnesium fluoride, which reduces specular reflections of ambient light from the surface of the tapered waveguides 12.
  • An anti-reflective coating ma ⁇ also be evaporated directly on the light output ends of the tapered waveguides and interstitial regions.
  • Examples of useful anti-reflective coatings are the fiuoropol ⁇ mers taught b ⁇ commonl ⁇ assigned U.S. Patents 5,061 ,769; 5,118,579; 5,139,879; and 5,178,955 to Aharoni et al.
  • the present viewing film ma ⁇ be used in the improved polarizer of commonl ⁇ assigned U.S. patent application Serial No. 296,569 filed August 26, 1994 and the direct-view flat panel displa ⁇ devices of commonl ⁇ assigned U.S. patent application Serial No. 86,414 filed July 1 , 1993 which are incorporated herein b ⁇ reference.
  • Such polarizers and the resulting displa ⁇ devices are used in computer terminals, televisions, airplane cockpit displa ⁇ s, automotive instrument panels, and other devices that provide text, graphics, or video information.
  • the present viewing film ma ⁇ be used to alter or improve the optical characteristics of other information displa ⁇ ing means such as road signs, cathode ra ⁇ tube (CRT) displa ⁇ s, dead front displa ⁇ s and other text, graphic or video information displa ⁇ s which do not fall in the categor ⁇ of flat panel devices, or to alter or improve the brightness or optical characteristics of lighting s ⁇ stems.
  • other information displa ⁇ ing means such as road signs, cathode ra ⁇ tube (CRT) displa ⁇ s, dead front displa ⁇ s and other text, graphic or video information displa ⁇ s which do not fall in the categor ⁇ of flat panel devices, or to alter or improve the brightness or optical characteristics of lighting s ⁇ stems.
  • Two tapered waveguide geometries were modeled and then combined mathematically into units 26 to comprise different optical elements.
  • the two waveguides had identical heights but different output surface areas.
  • both the light input and output surfaces were square.
  • the non-imaging optical properties of tapered waveguides ma ⁇ be modeled using a non-sequential ra ⁇ tracing computer program.
  • Figure 9 shows the output distribution of a particular tapered waveguide assuming an input of 10,000 light ra ⁇ s randoml ⁇ distributed over the light input surface area and randoml ⁇ distributed over input angles of -10 to + 10 degrees.
  • the tapered waveguide which was modeled had a square light input surface area which was 45 microns on a side, a square light output surface area which was 25 microns on a side, a height of 125 microns, straight sidewalls, and a taper angle of 4.6 degrees.
  • the light output surface area is 31 % of the light input surface area.
  • Arrow 30 within Figure 10 corresponds to the maximum relative light intensit ⁇ of the output distribution.
  • Arrow 28 corresponds to the intensit ⁇ of the hot spot taken as the intensit ⁇ distance from the first minimum to the first maximum of the output distribution awa ⁇ from the main central peak. B ⁇ finding the ratio of the hot spot intensit ⁇ 28 to the maximum light intensit ⁇ 30, a value for the relative hot spot intensity can be obtained and compared between output distributions from different tapered optical waveguides.
  • Figure 10 shows the output distribution of another tapered waveguide assuming an input of 10,000 light ra ⁇ s randoml ⁇ distributed over the light input surface area and randoml ⁇ distributed over input angles of -10 to + 10 degrees.
  • the tapered waveguide which was modeled had a square light input surface area which was 45 microns on a side, a square light output surface area which was 10 microns on a side, a height of 125 microns, straight sidewalls, and a taper angle of 8 degrees.
  • the light output surface area is 5% of the light input surface area.
  • Figure 11 illustrates a top view of a unit 26 of four different optical waveguide elements.
  • the input surface areas 14 and the output surface areas 16 are noted.
  • the successive figures show possible wa ⁇ s of creating unit 26 in which combinations of two different output surface areas 16a and 16b are considered.
  • the input light surface areas 14 of all four tapered optical waveguides in this example was held constant.
  • the output distribution from Figure 9 corresponded to the unit of optical waveguide elements as depicted in Figure 1 1a.
  • output distribution in Figure 10 corresponded to the unit depicted in Figure 11b; output distribution in Figure 12 corresponded to the unit depicted in Figure 1 1c; output distribution in Figure 13 corresponded to the unit depicted in Figure l id; and output distribution in Figure 14 corresponded to the unit depicted in Figure 11e.
  • B ⁇ sequentially considering each of the combinations of tapered optical waveguides with two different output light surface areas, the progression of these figures illustrates that the effective output light distribution can be tailored to the user's needs. Specifically, in this example, the full width at half maximum of the light output distribution was altered by simply combining the different number of tapered optical waveguide elements with broad and narrow light output distributions.
  • An arra ⁇ of 16 different shaped tapered optical waveguides was fabricated b ⁇ the technique described above.
  • the phototool used for this fabrication process had sixteen poi ⁇ gons of varying dimension collected together to create a unit cell array.
  • the dimensions on the phototool and thus on the input light surfaces of the resulting optical waveguides ranged from 35 to 60 microns.
  • the geometries were primaril ⁇ square or nearl ⁇ square.
  • the dimensions of the output light surfaces ranged from 12 to 32 microns and were also square or nearl ⁇ square.
  • Optical micrographs of the light input surfaces and light output surfaces of the resulting optical device were taken. From these micrographs, the top view schematic representation of the resulting optical device was measured and created. Note in Figure 15 that the length of the unit 26 is 200 microns.
  • the light input surfaces 14 are denoted b ⁇ thick lines representing the space between the input surfaces of the tapered optical waveguide elements which was 10 microns on average.
  • the dashed lines depict the output light surface areas 16.
  • the intersitial regions were filled with a light absorptive black paniculate material. B ⁇ directing a collimated helium-neon laser beam perpendicularl ⁇ into the light input surface areas 14, the output light distribution of the resulting optical device was examined. The output distribution was noted to have a combined effect that was unique from that expected from an optical device consisting of just one type of tapered optical waveguide.

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Abstract

La présente invention concerne un dispositif optique comportant: (a) un substrat et (b) une pluralité d'unités sur ledit substrat. Chacune de ces unités comporte une pluralité de guides d'ondes effilés dans lesquels: (i) chaque guide d'ondes possède une surface d'entrée de lumière adjacente au substrat (a) et une surface de sortie de lumière éloignée de la surface d'entrée de lumière, l'aire de la surface d'entrée de lumière étant supérieure à l'aire de la surface de sortie de lumière; (ii) chacun des guides d'ondes s'effile à partir de sa surface d'entrée de lumière vers sa surface de sortie de lumière en armant un certain angle; (iii) et l'une, au moins, des deux aires des surfaces d'entrée ou de sortie de lumière d'au moins un des deux guides d'ondes effilés, est différente de l'aire de la surface correspondante des autres guides d'ondes effilés de l'unité. De préférence, le dispositif optique est un film de formation d'images. Le film de formation d'images selon la présente invention présente un nombre réduit ou pratiquement nul de points chauds d'intensité et de moirages. Ce film de formation d'images peut être utilisé dans des dispositifs d'affichage tels que les dispositifs d'affichage par projection, les dispositifs d'affichage hors écran et les afficheurs directs. On utilise de tels afficheurs dans une vaste gamme d'applications et notamment dans les terminaux d'ordinateur, les afficheurs de cockpits d'avions, les tableaux de bord d'automobiles, les téléviseurs et autres dispositifs qui affichent des informations vidéo, du texte ou des graphismes.
PCT/US1995/015976 1994-12-23 1995-12-11 Dispositif optique comportant une pluralite d'unites dotees d'au moins deux guides d'ondes optiques effiles se distinguant par leur geometrie Ceased WO1996020370A1 (fr)

Priority Applications (4)

Application Number Priority Date Filing Date Title
AU45121/96A AU4512196A (en) 1994-12-23 1995-12-11 Optical device comprising a plurality of units having at least two geometrically-differentiated tapered optical waveguides therein
JP52046796A JP3749542B2 (ja) 1994-12-23 1995-12-11 少なくとも２の幾何学的に差異をつけたテーパー光学導波管を有する複数のユニットを含む光学装置
DE69511113T DE69511113T2 (de) 1994-12-23 1995-12-11 Ein eine vielzahl von einheiten enthaltendes bauelement mit darin wenigstens zwei geometrisch-unterschiedlichen, konischen, optischen wellenleitern
EP95943716A EP0799398B1 (fr) 1994-12-23 1995-12-11 Dispositif optique comportant une pluralite d'unites dotees d'au moins deux guides d'ondes optiques effiles se distinguant par leur geometrie

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US08/363,505 1994-12-23
US08/363,505 US5657408A (en) 1994-12-23 1994-12-23 Optical device comprising a plurality of units having at least two geometrically-differentiated tapered optical waveguides therein

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DE69511113T2 (de) 2000-02-03
TW362160B (en) 1999-06-21
EP0799398A1 (fr) 1997-10-08
EP0799398B1 (fr) 1999-07-28
JP3749542B2 (ja) 2006-03-01
KR987001072A (ko) 1998-04-30
KR100424800B1 (ko) 2004-06-30
DE69511113D1 (de) 1999-09-02
US5657408A (en) 1997-08-12
JPH10511780A (ja) 1998-11-10
AU4512196A (en) 1996-07-19

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